Download Product User Manual - Gerling Applied Engineering, Inc.

Product User Manual
♦
Model GA4010
3kW Magnetron Head
Document # 930002, Rev. 2
P.O. Box 580816 ♦ Modesto, CA 95358
www.2450mhz.com
Product User Manual
Model GA4010 - 3kW Magnetron Head
REV.
2
REVISION HISTORY
DESCRIPTION
MISC. UPDATES
Page 2
DATE
13FEB04
APPROVAL
JFG
WARRANTY
Products manufactured and sold by Gerling Applied Engineering, Inc. (“GAE”) are warranted to be free of defects in materials and workmanship under normal use and service
for a period of twelve (12) months from the date of original shipment. GAE’s obligation
under this warranty is limited to repairing or replacing, at GAE’s option, all nonconsumable component parts. Consumable parts are specifically excluded from this
warranty and may include, but are not be limited to, magnetrons, fuses, lamps, seals, orings, v-belts, and fluids. All warranty repairs are to be done at GAE’s facility or as otherwise authorized by GAE. All shipping charges for warranty repair or replacement are
the purchaser’s responsibility unless otherwise agreed to by GAE.
This warranty supercedes all other warranties, expressed or implied. No warranty is
given covering the product for any particular purpose other than as covered by the applicable product specifications. GAE assumes no liability in any event for incidental or
consequential damages, financial losses, penalties or other losses incurred in conjunction with the use of GAE products.
DOCUMENT CONVENTIONS
NOTE: Means the reader should take note.
Notes contain helpful information, suggestions, or references to other sections, chapters, or documents.
CAUTION: Means the reader should be careful.
You are doing
something that might result in equipment damage or loss of data.
WARNING: Means danger. A situation exists that could cause
bodily injury or death. All personnel must be aware of the hazards
involved with high voltage electrical circuitry and high power microwave devices.
Gerling Applied Engineering, Inc.
Modesto, CA
Product User Manual
Model GA4010 - 3kW Magnetron Head
Page 3
WARNING
This unit is capable of producing a microwave field that is potentially hazardous to operating personnel. It must never be connected or operated in a manner that allows a field
in excess of 10 milliwatts per square centimeter to be generated in an area accessible
to operating personnel. Contact GAE, Inc. for technical support prior to installation
and/or operation of this unit if there is any question or concern about microwave leakage.
All waveguide flange and electrical cable connections must be secure prior to operation
of this unit. Never operate the microwave generator without a properly rated absorbing
load attached. To ensure safe operation and prevent microwave leakage, the equipment
must be periodically inspected and maintained as required or recommended.
WARNING
Lethal voltages may exist inside this unit during operation. All maintenance and service
must be done by qualified technical personnel only. Under no circumstances should
improperly trained or underskilled personnel be allowed access inside this unit.
Gerling Applied Engineering, Inc.
Modesto, CA
Product User Manual
Model GA4010 - 3kW Magnetron Head
Page 4
TABLE OF CONTENTS
EQUIPMENT DESCRIPTION ..................................................................... 5
Electrical Specifications
Mechanical Specifications
5
5
INSTALLATION ......................................................................................... 6
Preliminary Inspection
Facilities Requirements
Mounting Position
Electrical Connections
Water Cooling
Microwave Output
6
6
6
6
6
7
BASIC OPERATION .................................................................................. 8
System Control
Power Control
Filament Voltage Control
8
8
8
USER MAINTENANCE .............................................................................. 9
Magnetron and Electromagnet Replacement
9
ATTACHMENTS:
Document Type
Drawing
Tech. Serv. Doc.
Number
910221
940002
Gerling Applied Engineering, Inc.
Title
Schematic Diagram, GA4010
Magnetron/Electromagnet Removal and Replacement
Modesto, CA
Product User Manual
Model GA4010 - 3kW Magnetron Head
Page 5
EQUIPMENT DESCRIPTION
The model GA4010 3kW Magnetron Head is designed for use with
any one of several model high voltage power supplies (HVPS)
manufactured by AGL, Inc. or its predecessor companies
(ASTeX/Gerling Laboratories, Inc. and Gerling Laboratories). The
GA4010 is functionally identical to the Gerling Labs model GL107
and can be used with any of the following power supplies:
GL108
GL110
GL120
GL124
GL125
GL126
3kW
3kW
3kW
3kW
3kW
3kW
HV Supply, Medium Ripple, Bench Mount
HV Supply, Standard Waveform, Bench Mount
HV Supply, Low Ripple, Rack Mount
HV Supply, Low Ripple, Bench Mount
HV Supply, Standard Waveform, Rack Mount
HV Supply, Medium Ripple, Rack Mount
Electrical Specifications
Output Power
0 – 3kW, continuously adjustable
Magnetron
Model GA8002 (modified Hitachi 2M13104A)
Output Frequency
2450 MHz +/- 50 MHz
Output Flange
WR284 Round (with taper for quickdisconnect clamp)
Indicators
Standby On incandescent lamp (amber)
Microwave On incandescent lamp (red)
Mechanical Specifications
Cooling Air
Forced air provided by internal fans
Cooling Water
Flow: 1.0 gpm nominal (0.5 gpm min.)
Inlet pressure: 30 – 70 psig
Inlet temp: ambient dew point min., 30°C
max.
Ambient Conditions
Temperature: -10 to 50 °C non-operating;
10 to 40 °C operating
Relative Humidity: 0 to 90%, noncondensing
Overall Dimensions
Chassis: 12” wide x 12” deep x 15” high
Waveguide extension: 2”
Net Weight
52 lb. (23.6 kgm)
Gerling Applied Engineering, Inc.
Modesto, CA
Product User Manual
Model GA4010 - 3kW Magnetron Head
Page 6
INSTALLATION
Preliminary Inspection
Upon arrival at the installation site the GA4010 should be thoroughly inspected for damage or wear caused during shipping. Any
visible damage to the packaging material or GA4010 should be
noted and reported immediately to the shipping company in accordance with standard claims procedures.
Facilities Requirements
• Electrical Power: All electrical power required by the GA4010 is
provided by the HVPS with which the GA4010 is used.
•
Ventilation: Adequate clearance must be provided near the ventilation ports on the front, back and top of the GA4010 such that
air is allowed to flow without restriction.
•
Environment: Indoors only, must be clean and dry.
Mounting Position
The GA4010 may be mounted on a horizontal surface such that the
broad wall of the output waveguide is horizontal. Orientation may
be either normal (magnetron up) or inverted (magnetron down) as
long as the axis of the magnetron is vertical. Maximum allowable tilt
of the magnetron axis is 5 degrees.
Electrical Connections
• Control Power: 9-pin cable connects between HVPS and J1 on
GA4010.
• High Voltage: 2-pin cable connects between HVPS and J3 on
GA4010.
Water Cooling
The magnetron contained within the magnetron head requires water cooling during operation. The nominal water flow is 1.0 gpm and
the minimum required flow is 0.5 gpm. An internal solenoid valve
automatically turns on water flow whenever the system is in operation. It is recommended that a source of water be permanently connected and pressurized at all times to ensure the availability of
cooling water during operation.
The water source must be connected to the upper connection fitting
and the drain connected to the lower fitting. The connection fittings
provided with the GA4010 are self-sealing to allow disconnection
while under pressure.
Gerling Applied Engineering, Inc.
Modesto, CA
Product User Manual
Model GA4010 - 3kW Magnetron Head
Page 7
The self-sealing water connection fittings prevent water from draining when the source and drain are disconnected. To prevent internal damage to the GA4010, steps must be taken to drain the water
prior to storage or shipping in the event that freezing temperatures
may be encountered.
CAUTION: Permanent damage to the magnetron can occur if
the GA4010 is operated without adequate water flow. It is recommended that a suitable external water flow interlock device be installed on the drain side of the water connections and its electrical
contacts be included in the interlock chain of the HVPS.
CAUTION: The minimum inlet temperature of the cooling water
must be above the ambient dew point temperature. Allowing the
cooling water inlet temperature to drop below the ambient dew
point can allow moisture condensation inside the microwave generator and/or waveguide circulator and cause equipment damage.
Microwave Output
The GA4010 must be connected to a suitable waveguide load
which prevents excessive microwave energy leakage and/or reflected power.
Microwave Leakage – Regulatory limits for microwave leakage relate to standards for human safety and interference with other electronic devices. Standards for human safety as adopted by OSHA,
the International Electrotechnical Commission (IEC) and other
regulatory agencies limit leakage to 5 mW/cm2 measured at 5 cm
from the leakage source under normal operating conditions, and 10
mW/cm2 at 5 cm from the source under abnormal operating conditions. The U.S. Federal Communications Commission (FCC) has
established regulations limiting the emission of energy at frequencies outside the ISM bands. The GA4010 meets these requirements when connected to a suitable waveguide load.
Reflected Power – Microwave power that is reflected back to the
magnetron from a waveguide load can cause permanent damage
to and/or shorten the life of the magnetron. Care should be taken to
ensure that reflected power does not exceed 200 Watts. It is recommended that a suitable waveguide isolator be connected at the
output flange of the GA4010 to prevent reflected power from reaching the magnetron.
Gerling Applied Engineering, Inc.
Modesto, CA
Product User Manual
Model GA4010 - 3kW Magnetron Head
Page 8
BASIC OPERATION
The purpose of this discussion is to provide a basic understanding
of the system operation such that a reasonably skilled electronics
technician can perform basic diagnostics and service in the event of
malfunction. However, any problem that develops which can not be
diagnosed and solved by reference to the following discussion
should be referred to GAE, Inc. for further assistance.
System Control
The HVPS to which the GA4010 is connected contains circuitry that
generates a 24 Vac control signal when the “System Start” button is
pressed. This “system on” signal (J1, pin B) places the system in
“Standby” mode and turns on the water solenoid valve and
“Standby On” indicator in the GA4010. The signal then passes back
to the HVPS as an “interlock return” signal (J1, pin F) and ensures
proper connection of the GA4010 prior to turning on high voltage.
Simultaneously, a 120 Vac signal is delivered to the GA4010 (J1,
pin A) which turns on the cooling fans. The electromagnet and filament voltage control circuits located in the HVPS are also activated
at this time and their respective signals are delivered to the
GA4010 (J1, pins C, D and E).
Once all of the external and system interlocks are satisfied, the “Microwave On” button on the HVPS can be pressed to turn on high
voltage and place the system into “Operate” mode. This then sends
another 24 Vac control to the GA4010 (J1, pin H) and turns on the
“Microwave On” indicator. High voltage is also delivered to the
GA4010 (J3, pin A) at this time.
Power Control
Microwave power output is controlled by varying the current
through the electromagnet while maintaining a fixed high voltage on
the anode of the magnetron. The electromagnet establishes a
magnetic field inside the magnetron which in turn determines the
level of current that is allowed to pass through the magnetron for a
given anode voltage. With the anode voltage fixed, decreasing the
electromagnet current will decrease the magnet field and allow
more anode current resulting in higher output power.
Filament Voltage Control
The filament voltage must be reduced as microwave output power
is increased. It is necessary to maintain a constant (or nearly constant) filament temperature during operation, so the filament voltage is reduced to compensate for excess heating caused by electron back-bombardment as output power is increased.
Gerling Applied Engineering, Inc.
Modesto, CA
Product User Manual
Model GA4010 - 3kW Magnetron Head
Page 9
USER MAINTENANCE
All service and repair of the GA4010 should be performed by a
properly qualified service technician having a reasonable background in high voltage power supplies. GAE, Inc. personnel are
available to assist with any maintenance problem.
WARNING: Lethal voltages can exist inside the GA4010 during
periods of operation. Always disconnect line power before performing any type of service. All service personnel must be aware of the
hazards involved with high voltage electrical circuitry and high
power microwave devices.
WARNING: Excessive leakage of microwave energy generated
by the GA4010 can be lethal. Never connect line power to the system without a suitable waveguide load connected to the output
flange of the GA4010.
CAUTION: Permanent damage to the magnetron can occur if
the GA4010 is operated without adequate water flow. It is recommended that a suitable external water flow interlock device be installed on the drain side of the water connections and its electrical
contacts be included in the interlock chain of the HVPS.
Magnetron and Electromagnet Replacement
Refer to Technical Service Document # 940002 for procedures to
remove and replace the magnetron and electromagnet. The initial
set-up procedures as outlined in the HVPS operation manual
should be performed after replacement of either of these two components. Specific attention should be given to the procedures for
power output and filament voltage adjustment.
Gerling Applied Engineering, Inc.
Modesto, CA
Technical Service Document
TSD No: 940002
Rev: B
Page: 1 of 4
APPROVALS
INITIALS
JFG
Drawn
Engineering
Manufacturing
Marketing
1.
Magnetron and Electromagnet
Removal and Installation Procedure
DATE
15APR99
REV
B
REVISIONS
DESCRIPTION
Redrawn
DATE
04MAR00
APPR
JFG
Introduction
1.1.
Scope
This procedure covers microwave generators currently using the model GA8002 magnetron
manufactured by GAE, Inc. It may also be used to install the GA8002 into generators currently
using the model AG9131 magnetron manufactured by AGL, Inc.
NOTE: This procedure can NOT be used to install the GA8002 magnetron into microwave
generators currently using the model GL131C magnetron manufactured by AGL, Inc. (formerly
Gerling Labs and ASTeX/Gerling Labs, Inc.) or the model L-3858 magnetron manufactured by
Litton Industries. These generators must first be updated for use with the GA8002 magnetron
(or AG9131) as described in GAE Technical Service Document # 940001.
1.2.
Reference Documents
Drawing 910220
2.
Magnetron/Electromagnet Removal and Replacement
Magnetron Removal and Installation
2.1.
Removal
2.1.1. Refer to Drawing 910220 for location of ITEMS referenced in the following discussion.
2.1.2. DISCONNECT THE POWER SOURCE FROM THE ELECTRIC POWER
CONNECTION AND COOLING WATER CONNECTION.
2.1.3. Remove outer cover(s) as necessary to gain access to the magnetron housing.
2.1.4. Disconnect the water hoses from the magnetron. MAKE SURE THAT WATER DOES
NOT ENTER THE ELECTROMAGNET HOUSING. It is recommended that a rag or
other absorbent material be placed around the cooling tubes while disconnecting the
hoses.
2.1.5. Carefully disconnect the Fan Cord (not referenced) from the FAN.
2.1.6. Remove the four screws which secure TOP COVER and remove the FAN and TOP
COVER as an assembly from the power source.
2.1.7. Remove the two screws holding the vertical SIDE COVER at the bottom of the cover.
Remove the cover from the power source.
 2000 GERLING APPLIED ENGINEERING, INC. ♦ P.O. BOX 580816 ♦ MODESTO, CA 95358
Phone: 209-527-8960 ♦ Fax: 209-527-5385 ♦ Email: [email protected] ♦ Web: www.2450mhz.com
Technical Service Document
TSD No: 940002
Rev: B
Page: 2 of 4
Magnetron and Electromagnet
Removal and Installation Procedure
2.1.8. With a suitable Phillips screwdriver carefully loosen and remove the screws securing the
inside leads on the HV FEED-THRU ASSY to the magnetron filament leads.
2.1.9. Carefully bend the magnetron filament leads straight up.
2.1.10. Remove the three #8 kepnuts that hold the UPPER POLE PIECE to the UPPER
ELECTROMAGNET RETAINER.
2.1.11. Remove the UPPER POLE PIECE.
2.1.12. Remove the used GA8002 MAGNETRON. Save the thrust ring washer which is resting
on top of the magnetron.
2.1.13. Optional: Return the used magnetron to GAE, Inc. for a no-cost failure analysis report.
2.2.
Installation
2.2.1. Refer to Drawing 910220 for location of ITEMS referenced in the following discussion.
2.2.2. Insert the new GA8002 MAGNETRON into the housing and ensure it is properly seated
into the socket of the LOWER POLE PIECE.
2.2.3. Ensure that the thrust ring washer is resting on top of the magnetron core assembly and
around filament lead mast. Note that only one thrust ring washer is required and that
one may have been supplied with the replacement GA8002 magnetron.
2.2.4. Install the UPPER POLE PIECE onto the UPPER ELECTROMAGNET RETAINER with
the flange towards the bottom. Tighten the #8 nuts previously removed until they are just
snug. Do not over tighten.
2.2.5. Install and hand tighten the THRUST RING while gently rocking the magnetron by its
cooling lines until the magnetron is firmly seated and snug in place. The stem of the
magnetron must be centered and vertical. Finish tightening the three #8 nuts securing
the UPPER POLE PIECE.
2.2.6. Carefully insert the THRUST RING INSULATOR around the magnetron filament leads
and into the THRUST RING.
2.2.7. Carefully bend the magnetron filament leads so that they are positioned towards the HV
Feedthru leads. Secure the filament leads to the leads from the HV Feedthru (attached
to the filament housing wall) using the previously removed screws and nuts. Position
these connections such that they are separated from each other and approximately midway between the bottom and top of the filament housing.
2.2.8. Reinstall the housing SIDE COVER and fasten it to the FILAMENT HOUSING with two
the screws previously removed.
2.2.9. Install the TOP COVER and FAN assembly and secure it to the filament housing with
the four sheet metal screws previously removed.
 2000 GERLING APPLIED ENGINEERING, INC. ♦ P.O. BOX 580816 ♦ MODESTO, CA 95358
Phone: 209-527-8960 ♦ Fax: 209-527-5385 ♦ Email: [email protected] ♦ Web: www.2450mhz.com
Technical Service Document
TSD No: 940002
Rev: B
Page: 3 of 4
Magnetron and Electromagnet
Removal and Installation Procedure
2.2.10. Reattach the fan cord to the FAN.
2.2.11. Reattach the cooling hoses to the cooling lines of the magnetron. DO NOT OVER
TIGHTEN THE BANDS.
2.2.12. Replace outer access cover(s).
2.2.13. Perform the Set Up Procedures for installation of a new magnetron as described in the
Installation, Operation and Maintenance Manual which was originally provided with the
generator.
3.
Electromagnet Removal and Installation
3.1.
Removal
3.1.1. Refer to Drawing 910220 for location of ITEMS referenced in the following discussion.
3.1.2. DISCONNECT THE POWER SOURCE FROM THE ELECTRIC POWER
CONNECTION AND COOLING WATER CONNECTION.
3.1.3. Follow steps 2.1.3 through 2.1.12 as outlined in the Standard Retrofit Procedure above
for removal of the magnetron.
3.1.4. Remove the brown phenolic insulator block from around the connection between the
filament transformer HV leads and HV FEEDTHRU LEADS.
3.1.5. Disconnect the filament transformer leads from the feedthru leads.
3.1.6. Disconnect the electromagnet leads from the two-position terminal block located on the
side of the housing near the HV feedthru leads.
3.1.7. Remove the four sets of 3/8-16 BOLTS (with nuts and washers) and left off the UPPER
ELECTROMAGNET RETAINER with the filament housing intact.
3.1.8. Remove the ELECTROMAGNET along with the INSULATORS above (not below) the
electromagnet. Also remove the plastic CENTERING RING.
3.2.
Installation
3.2.1. Refer to Drawing 910220 for location of ITEMS referenced in the following discussion.
3.2.5. Set the ELECTROMAGNET onto the lower INSULATOR with the leads on top and
towards the rear of the power source (away from the output flange).
3.2.6. Install the plastic CENTERING RING into the space between the ELECTROMAGNET
and LOWER POLE PIECE.
 2000 GERLING APPLIED ENGINEERING, INC. ♦ P.O. BOX 580816 ♦ MODESTO, CA 95358
Phone: 209-527-8960 ♦ Fax: 209-527-5385 ♦ Email: [email protected] ♦ Web: www.2450mhz.com
Technical Service Document
TSD No: 940002
Rev: B
Page: 4 of 4
Magnetron and Electromagnet
Removal and Installation Procedure
3.2.7. Set the other electromagnet Insulator on top of the ELECTROMAGNET and properly
centered. Be sure the notches are aligned with those of the lower Insulator and the
launch section assembly mounting holes.
3.2.8. Set the UPPER ELECTROMAGNET RETAINER (with filament housing attached) over
the ELECTROMAGNET with the mounting holes aligned with those of the launch
section assembly.
3.2.9. Install the four 3/8-16 BOLTS through the launch section mounting holes from the
bottom. Install the flat washers, split-ring lockwashers, and the hex nuts in that order.
Tighten the hex nuts until the lockwasher is approximately one-half compressed (this
is to allow for thermal expansion of the electromagnet).
3.2.10. Connect the leads of the electromagnet to the two-position terminal block (the order of
connection is not important).
3.2.11. Connect the filament transformer HV leads to the HV FEEDTHRU LEADS. Also attach
the flying HV lead from the rectifier assembly (on top of the plate transformer) to the
near HV feedthru lead. Install the phenolic insulator block over these HV lead
connections.
3.2.12. Follow steps 2.2.2 through 2.2.13 as outlined in the Standard Retrofit Procedure above
for installation of the new GA8002 MAGNETRON.
 2000 GERLING APPLIED ENGINEERING, INC. ♦ P.O. BOX 580816 ♦ MODESTO, CA 95358
Phone: 209-527-8960 ♦ Fax: 209-527-5385 ♦ Email: [email protected] ♦ Web: www.2450mhz.com